Bending Thin Walled Aluminium to a Tight Radius


How to bend thin walled aluminium to a tight radius without damaging?

This is a common challenge we have encountered in high quality aluminium bending services.

Years of experience in bending aluminium has shown us just how easily thin walled aluminium sections can be damaged. This has led to many late nights pulling our hair out trying to find a solution, and thankfully, we have.


Thin walled Extrusion for tight aluminium bending


We have developed a carefully set up process. One that allows us to bend impossibly thin walled sections with very little to no risk of damage. This process is surprisingly simple and easily repeatable. We have already used it in a number of fantastic projects over the years and results have been incredible.


Thin Walled aluminium curved to a tight radius (High)Thin Walled aluminium curved to a tight radius (Low)



The Solution

We use a combination of specially design tooling and a customized machines to carefully fit the delicate material. Therefore the material is properly supported and guided through the bending process. Finally, once we find the correct set up we track every step to ensure repeatability.

Our intensive quality checking system tracks every issue or error in the bending process. Specifically so that we can quickly address it. While almost all sections will have the same general issues during testing, individual sections can also bring up unique problems.

Our latest example of this was completing a run of curved aluminium box trims to be used by a prominent aviation company.

Thin walled aluminium curved to tight radius for first aid box

Thin walled aluminium curved to tight radius for first aid boxThin walled aluminium curved to tight radius for first aid box (2)


The hurdle of clean, tightly bent thin walled aluminium has been a thorn in the side of aluminium benders for years. In this case we took the challenge and found a new way to approach it. As a result producing a clean solution to a sometimes messy job.

Exceptional 3 Dimensional Bends, impossibly tight radii, and the highest quality final products. These are the aspects that our customers have come to expect when receiving a curved aluminium section from Alubend.

Do you have a project that’s been turned away?

Do you have an idea you think might be impossible?

Get in touch and let us show you that we can bend just about anything you can imagine.